Foam pod foundation system and method of assembly

ABSTRACT

A building foundation that includes a plurality of foam pods disposed on a graded surface and a concrete structure disposed around the plurality of foam pods.

TECHNICAL FIELD

The present disclosure relates generally to foundation systems, and more specifically to a foam pod foundation system and method of assembly.

BACKGROUND OF THE INVENTION

Foundation systems typically use post-tensioned slabs or piers and beams.

SUMMARY OF THE INVENTION

A building foundation is disclosed that includes a plurality of foam pods disposed on a graded surface and a concrete structure disposed around the plurality of foam pods.

Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings may be to scale, but emphasis is placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:

FIG. 1 is a diagram of a system that uses foam pods for a foundation, in accordance with an example embodiment of the present disclosure;

FIG. 2 is a diagram of an elevation view of a system that uses foam pods for a foundation, in accordance with an example embodiment of the present disclosure; and

FIG. 3 is a diagram of an algorithm for fabricating a foundation that uses foam pods, in accordance with an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures may be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.

FIG. 1 is a diagram of a system 100 that uses foam pods for a foundation, in accordance with an example embodiment of the present disclosure. System 100 includes foam pods 102, spacers 104, post tension cable 106, form 108 and staple 110, which can be fabricated as discussed below.

Foam pods 102 can be fabricated from polymers, elastomers, rubbers, other suitable materials or a suitable combination of materials. In one example embodiment, foam pods 102 can be fabricated from partially recycled polystyrene that is molded into quadrilateral pods, such as square pods having dimensions of 36″ by 36″ and a suitable height, such as 12″, or other suitable dimensions. Foam pods 102 can have a density of 1.3 lb/cf or other suitable densities. Foam pods 102 can be disposed on a graded surface that has been treated with a vapor barrier or in other suitable manners.

Spacers 104 can be fabricated from polymers, elastomers, rubbers, other suitable materials or a suitable combination of materials. In one example embodiment, spacers 104 can be circular disc spacers having a predetermined radius (such as 6 inches) and a predetermined thickness (such as 2 inches) and that are made using plastic injection molding or other suitable processes.

Post tension cable 106 can be formed from plastic, steel, galvanized steel or other suitable material, and is disposed between foam pods or in other suitable locations. In one example embodiment, post tension cable 106 can be installed at a first level that is located at a point along the height of foam pods 102, and at a second level above the height of foam pods 102, as further described below. Spacers 104 can be disposed on the post tension cable 106 between foam pods 102 at the lower level to maintain even and consistent spacing. Staples 110 can be used to support the post tension cable 106 at the second level.

Form 108 can be fabricated from steel or other suitable materials, and can be used to align post tension cables 106, such as by temporarily attaching post tension cables 106 to form 108 or in other suitable manners. Form 108 can be configured for removal after concrete has been poured and has set or in other suitable manners.

Staples 110 can be fabricated from plastic, steel, galvanized steel or other suitable materials, and can be used to provide proper spacing between foam pods 102, to support post tension cables 106 and for other suitable purposes. In one example embodiment, staples 110 can be installed in series, so as to ensure that proper spacing is provided and to avoid the inadvertent creation of offsets or discontinuities.

In operation, system 100 can be used to provide a foundation for a building that is easy to install, that can be installed quickly and that can be installed at a substantially lower cost than prior art foundations. System 100 allows multiple workers to install components of system 100 such as foam pods 102, spacers 104 and staples 110 in parallel, so as to decrease the amount of time required for installation. Foam pods 102 can be pre-fabricated and delivered to the job site just in time for construction, which decreases fabrication and material storage costs. For example, for pier and beam foundations, it is often necessary to dig holes for each pier using specialized equipment, then to construct each pier, which is time consuming and which requires specialized skills. Foam pods 102 eliminate the need for such construction activities.

FIG. 2 is a diagram 200 of an elevation view of a system that uses foam pods for a foundation, in accordance with an example embodiment of the present disclosure. Elevation view 200 includes foam pods 102, spacers 104, form 108, staples 110, vapor barrier 202, concrete 204 and finished floor 206, which can be fabricated as discussed below.

In addition to the components of system 100 as discussed above, diagram 200 shows a vapor barrier 202, which can be installed after the site has been graded but prior to the installation of foam pods 102. After all foam pods 102 have been installed and properly placed using spacers 104 and staples 110, concrete 204 can be poured until the finished floor 206 level has been reached. Post-pour treatment of concrete 204 can then be performed, such as leveling, smoothing, sealing and so forth. Form 108 can be removed after concrete 104 has set, and post tensioning of the post tension cables 106 (not explicitly shown) can then be performed.

FIG. 3 is a diagram of an algorithm 300 for fabricating a foundation that uses foam pods, in accordance with an example embodiment of the present disclosure. Algorithm 300 can be performed by one or more processors to track the status of associated manual activities or in other suitable manners.

Algorithm 300 begins at 302, where a site is fine graded. In one example embodiment, a system can be used to generate a user interface that includes a status notice for scheduling grading, to schedule equipment or workers or for other suitable purposes, including one or more controls for updating status, rescheduling or other suitable functions. In this example embodiment, the site can be graded to a suitable depth below the finished floor level, such as 17″ for installations where the foam pods are 12″ in height and a 5″ over layer of concrete is to be installed, but other suitable dimensions can also or alternatively be used. The present disclosure thus avoids the need for slab undercutting, moisture injection of expansive soils or other treatments. Prior to grading, the surface can be compacted where needed, forms can be installed, underground plumbing and electrical facilities can be installed, trenches and pads can be compacted and other suitable processes or activities can also or alternatively be performed, and suitable notifications and user controls can be generated to manage progress and to report any delays or interruptions, such as by generating an alert. The user interface can also or alternatively include status indicators and controls for one or more of these additional activities. The algorithm then proceeds to 304.

At 304, a status notice and controls are generated for activities associated with installing a concrete vapor barrier, such as polyethylene plastic sheeting, resin implanted plastic sheeting or other suitable materials. In one example embodiment, the vapor barrier can be installed on an entire slab footprint, on predetermined portions of the slab footprint or in other suitable manners. The algorithm then proceeds to 306.

At 306, a status notice and controls are generated for activities associated with installing post tension cables or other suitable tensioning equipment, and the post tension cables are then installed. In one example embodiment, a pour strip can be provided, such as where the available post tension cable length is shorter than the pad dimensions or in other suitable embodiments. The algorithm then proceeds to 308.

At 308, a status notice and controls are generated for activities associated with installing spacers at each side of the locations where the foam pods will be installed. In one example embodiment the spacers can be 6″ circular disc structures, but other suitable shapes and configurations of spacers can also or alternatively be used. The spacers can be configured to connect to and support post tension cables, such as to maintain their height over the grade at 3″ or other suitable distances. The algorithm then proceeds to 310.

At 310, a status notice and controls are generated for activities associated with installing foam pods. In one example embodiment, the foam pods can be delivered “just in time” to reduce or eliminate storage requirements. In this embodiment, the number of workers available to install the pods and the installation rate can be used to schedule deliveries of the foam pods, where suitable notices and controls for reporting the installation rate, the number of installed foam pods, the number of remaining foam pods, a number of foam pods to be delivered on a predetermined day or within a predetermined time, completion of installation, interruption of installation, alerts for any status, the number of workers, the number of available foam pods or other suitable data and functions can be generated to assist with scheduling activities. The algorithm then proceeds to 312.

At 312, a status notice and controls are generated for activities associated with installing staples at foam pod. In one example embodiment, one or more staples can be installed at each foam pod, such as to serve as an additional 6″ spacer, to support an upper post tension cable into the 5″ thick slab by a suitable amount such as 2″ for additional strength of the slab, or for other suitable purposes. The use of these staples can eliminate the need for rebar in the slab or other strengthening components. The algorithm then proceeds to 314.

At 314, a status notice and controls are generated for activities associated with installing final system components. In one example embodiment, additional reinforcing can be provided for walls, such as concrete masonry wall blocks and vertical rebar, tilt wall, cutting penetrations for plumbing and electrical facilities and other suitable activities. The algorithm then proceeds to 316.

At 316, a status notice and controls are generated for activities associated with pouring concrete. In one example embodiment, a single-ended concrete delivery hose and boom can be used to provide concrete at the top of each pod, to allow the concrete to flow into grade beams, followed by vibration of the concrete into place, or other suitable processes can also or alternatively be used. Notifications and controls can be generated when installation of concrete is completed, if installation of concrete has been interrupted, or for other suitable purposes. The algorithm then proceeds to 318.

At 318, a status notice and controls are generated for activities associated with stripping the concrete forms to expose the post tension cables. In one example embodiment, the notice and controls can be modified based on an engineer's recommendation, the concrete mix design for the site, to allow for proper cure times or for other suitable purposes. The algorithm then proceeds to 320.

At 320, a status notice and controls are generated for activities associated with applying tension to the post-tensioning cables. In one example embodiment, the cables can be tensions one or more days after the pour, and then after the concrete has met its design strength after curing, the cables can be further tensioned to comply with a cable supplier's recommendations, such as from 7-10% elongated length of original cable length to reach desired strength. Scheduling notices can be generated for a third party testing company to document the elongation, submit their findings to the engineer of record, to verify that the elongation meets the specified standards and for other suitable purposes. Once it is determined that the elongation is sufficient, the post tension cable is cut, and the pockets are grouted.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

As used herein, “hardware” can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. As used herein, “software” can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications, on one or more processors (where a processor includes one or more microcomputers or other suitable data processing units, memory devices, input-output devices, displays, data input devices such as a keyboard or a mouse, peripherals such as printers and speakers, associated drivers, control cards, power sources, network devices, docking station devices, or other suitable devices operating under control of software systems in conjunction with the processor or other devices), or other suitable software structures. In one exemplary embodiment, software can include one or more lines of code or other suitable software structures operating in a general purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “couple” and its cognate terms, such as “couples” and “coupled,” can include a physical connection (such as a copper conductor), a virtual connection (such as through randomly assigned memory locations of a data memory device), a logical connection (such as through logical gates of a semiconducting device), other suitable connections, or a suitable combination of such connections. The term “data” can refer to a suitable structure for using, conveying or storing data, such as a data field, a data buffer, a data message having the data value and sender/receiver address data, a control message having the data value and one or more operators that cause the receiving system or component to perform a function using the data, or other suitable hardware or software components for the electronic processing of data.

In general, a software system is a system that operates on a processor to perform predetermined functions in response to predetermined data fields. A software system is typically created as an algorithmic source code by a human programmer, and the source code algorithm is then compiled into a machine language algorithm with the source code algorithm functions, and linked to the specific input/output devices, dynamic link libraries and other specific hardware and software components of a processor, which converts the processor from a general purpose processor into a specific purpose processor. This well-known process for implementing an algorithm using a processor should require no explanation for one of even rudimentary skill in the art. For example, a system can be defined by the function it performs and the data fields that it performs the function on. As used herein, a NAME system, where NAME is typically the name of the general function that is performed by the system, refers to a software system that is configured to operate on a processor and to perform the disclosed function on the disclosed data fields. A system can receive one or more data inputs, such as data fields, user-entered data, control data in response to a user prompt or other suitable data, and can determine an action to take based on an algorithm, such as to proceed to a next algorithmic step if data is received, to repeat a prompt if data is not received, to perform a mathematical operation on two data fields, to sort or display data fields or to perform other suitable well-known algorithmic functions. Unless a specific algorithm is disclosed, then any suitable algorithm that would be known to one of skill in the art for performing the function using the associated data fields is contemplated as falling within the scope of the disclosure. For example, a message system that generates a message that includes a sender address field, a recipient address field and a message field would encompass software operating on a processor that can obtain the sender address field, recipient address field and message field from a suitable system or device of the processor, such as a buffer device or buffer system, can assemble the sender address field, recipient address field and message field into a suitable electronic message format (such as an electronic mail message, a TCP/IP message or any other suitable message format that has a sender address field, a recipient address field and message field), and can transmit the electronic message using electronic messaging systems and devices of the processor over a communications medium, such as a network. One of ordinary skill in the art would be able to provide the specific coding for a specific application based on the foregoing disclosure, which is intended to set forth exemplary embodiments of the present disclosure, and not to provide a tutorial for someone having less than ordinary skill in the art, such as someone who is unfamiliar with programming or processors in a suitable programming language. A specific algorithm for performing a function can be provided in a flow chart form or in other suitable formats, where the data fields and associated functions can be set forth in an exemplary order of operations, where the order can be rearranged as suitable and is not intended to be limiting unless explicitly stated to be limiting.

It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. 

What is claimed is:
 1. A building foundation, comprising: a plurality of foam pods disposed on a graded surface; and a concrete structure disposed around the plurality of foam pods.
 2. The building foundation of claim 1 wherein the plurality of foam pods comprise a plurality of identical foam pods.
 3. The building foundation of claim 1 wherein the plurality of foam pods comprise a polystyrene foam.
 4. The building foundation of claim 1 wherein the plurality of foam pods comprise quadrilateral foam pods.
 5. The building foundation of claim 1 wherein the plurality of foam pods are spaced evenly.
 6. The building foundation of claim 1 further comprising a plurality of spacers between the foam pods.
 7. The building foundation of claim 1 further comprising a plurality of circular spacers between the foam pods.
 8. The building foundation of claim 1 further comprising a plurality of post-tension cables disposed in the concrete structure.
 9. The building foundation of claim 1 further comprising a plurality of post-tension cables disposed in the concrete structure at a first level and a second plurality of post-tension cables disposed in the concrete structure at a second level.
 10. A method for constructing a building foundation, comprising: generating a first user control using a data processing machine to initiate installation of a plurality of foam pods disposed on a graded surface; and generating a second user interface control after completion of the installation of the plurality of foam pods to initiate installation of a concrete structure disposed around the plurality of foam pods.
 11. The method of claim 10 wherein the first user control identifies a number of the plurality of foam pods.
 12. The method of claim 10 wherein the first user control identifies a number of the plurality of foam pods that remain to be installed.
 13. The method of claim 10 wherein the first user control identifies a number of the plurality of foam pods that have already been installed.
 14. The method of claim 10 wherein the first user control identifies when the graded surface has been completed.
 15. The method of claim 10 wherein the first user control identifies when installation of the plurality of foam pods has been completed.
 16. The method of claim 10 wherein the first user control identifies when installation of the plurality of foam pods has been interrupted.
 17. The method of claim 10 wherein the first user control identifies when installation of the concrete structure has been completed.
 18. The method of claim 10 wherein the first user control identifies when installation of the concrete structure has been interrupted.
 19. A method for forming a building foundation having a plurality of foam pods disposed on a graded surface, a concrete structure disposed around the plurality of foam pods, wherein the plurality of foam pods comprise a plurality of identical foam pods, wherein the plurality of foam pods comprise a polystyrene foam, wherein the plurality of foam pods comprise quadrilateral foam pods, wherein the plurality of foam pods are spaced evenly, a plurality of spacers between the foam pods, a plurality of circular spacers between the foam pods, a plurality of post-tension cables disposed in the concrete structure and a plurality of post-tension cables disposed in the concrete structure at a first level and a second plurality of post-tension cables disposed in the concrete structure at a second level, the method comprising: generating a first user control using a data processing machine to initiate installation of a plurality of foam pods disposed on a graded surface; generating a second user interface control after completion of the installation of the plurality of foam pods to initiate installation of a concrete structure disposed around the plurality of foam pods; wherein the first user control identifies a number of the plurality of foam pods; wherein the first user control identifies a number of the plurality of foam pods that remain to be installed; wherein the first user control identifies a number of the plurality of foam pods that have already been installed; wherein the first user control identifies when the graded surface has been completed; wherein the first user control identifies when installation of the plurality of foam pods has been completed; wherein the first user control identifies when installation of the plurality of foam pods has been interrupted; wherein the first user control identifies when installation of the concrete structure has been completed; and wherein the first user control identifies when installation of the concrete structure has been interrupted. 